Method and apparatus for winding and inserting stator coils

ABSTRACT

A completed set of stator coils is wound with the respective coils arrayed in horizontal sectors supported on a coil form which determines the length of the turns in each coil and corresponds to the length required by the geometry of the stator. The coils are distributed vertically to make the general dimensions of the copper cross section suitable for passage through the slot between the teeth on the stator. After the set of coils is wound, the stator is registered with the coils on the coil form such that a central plunger moving through the coil form simultaneously moves all the windings of the set through the central bore of the stator while simultaneously drawing the coil sides through the stator slots thus ultimately to position the set of coils in the proper location distributed on the poles of the stator.

United States Patent [1 1 Sedgewick [451 Aug. 7, 1973 METHOD AND APPARATUS FOR WINDING AND INSERTING STATOR COILS [76] Inventor: Richard D. Sedgewiek, 100 Home St., Dover, N.l-l.

[52] US. Cl. 140/921, 29/596 [58] Field of Search 140/921, 92.2; 29/205 D, 596

[56] References Cited UNITED STATES PATENTS 3,557,432 1/1971 Pavesi 140/922 3,559,699 2/1971 Droell 1 0/921 3,528,170 9/1970 Duff et a1 29/205 3,481,372 12/1969 Eminger et al. 140/921 Primary Examiner-Lowell A. Larson Attorney-Chittick, Pfund, Birch, Samuels & Gauthier [57] ABSTRACT A completed set of stator coils is wound with the respective coils arrayed in horizontal sectors supported on a coil form which determines the length of the turns in each coil and corresponds to the length required by the geometry of the stator. The coils are distributed vertically to make the general dimensions of the copper cross section suitable for passage through the slot between the teeth on the stator. After the set of coils is wound, the stator is registered with the coils on the coil form such that a central plunger moving through the coil form simultaneously moves all the windings of the set through the central bore of the stator while simultaneously drawing the coil sides through the stator slots thus ultimately to position the set of coils in the proper location distributed on the poles of the stator.

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INVENTOR RICHARD D. SEDGEWICK w X-A ML-MGQM ATTORNEYS METHOD AND APPARATUS FOR WINDING AND INSERTING STATOR COILS BACKGROUND OF THE INVENTION The field of this invention relates to the winding of coils for insertion in the stator slots of an electrical machine and the corresponding insertion of the coils which constitute the complete winding into the slots of the stator.

Many winding and inserting techniques are known in the prior art with the techniques employed being generally suitable for large gauge wire size and correspondingly large stators. Smaller sizes heretofore have generally been assembled by hand insertion of a previously wound set of coils which, when wound, are relatively self-supporting but nevertheless rather delicate. The fine wire size and small dimensions involved in miniature stators and the multiple pole configurations required for certain applications makes for an extremely difficult and tedious hand insertion operation. The prior art machines generally involve a one coil winding and insertion technique with the conductor either broken or maintained during the process or if a set of coils is to be inserted the winding of the boil set takes place with the coils in a physical position distribution which required their transfer through an intermediate instrumentality before they are properly located for the insertion operation. The patents to Mason U.S. Pat. No. 2,836,204, Hill, U.S. Pat. No. 3,151,638, Moore, U.S. Pat. No. 3,189,059, Schmoolevich et al., U.S. Pat. No. 3,191,638, Eminger et al., U.S. Pat. No. 3,481,372 and Hill, U.S. Pat. No. 3,508,316 are representative of the prior art of the aforementioned type.

SUMMARY OF THE INVENTION The present invention contemplates the winding of a coil set which constitutes a complete winding or a complete phase or other subdivision of a complete winding with a continuous conductor on a composite coil form which provides an individual coil supporting form for each coil in the set and with the coils arranged in sectors which correspond with their location on the sectors of the stator winding after insertion. The coil form may be a permanent part of the winding machine or a disposable unit such as an injection molded plastic form upon which the coils are wound and stored for subsequent insertion. In either event, the set of coils is wound in the sector configuration and maintained supported on the coil form with a spatial distribution that provides subsequent registry with the appropriate slots in the stator and a guiding relation for the turns of the coils as the coils are inserted which prevents damage to the turns of the windings. Since the coils are so supported, the insertion operation moves all of the coils simultaneously thereby simplifying the insertion operation and at the same time retainer wedges may be inserted to retain the coils in the stator slots. In the preferred embodiment, the coil form may comprise a slotted cylindrical mandrel, the sectors of which between adjacent mandrel slots represents exactly the circumferential distance between stator slots in which the opposite coil sides of a particular coil are to be inserted. This distance may encompass one or more teeth on the stator and the included stator slots if plural teeth are spanned, but in either event the edges of the cylindrical sector provide a guide which is in precise registry with the inner tooth face edges which define the slots into which the coil sides of a particular coil are to be inserted. A complete coil form comprises an inner cylindrical sector member and outer guides positioned as determined by the desired length of the coil turns for each coil and when the coil set has been wound on all of the cylindrical sectors of the coil form, insertion may be achieved by the axial motion ofa cylindrical plunger running through the center space defined within the cylindrical sectors to slide the wound coils axially therealong guided by the edges of the sectors into the appropriate slots of a stator which has been brought into regi'stry with the sector edges. Where the cylindrical sector portions are stationary and therefore dimensioned to correspond exactly with the dimensions of the stator which is to be loaded the coils are wound by means of a hollow needle guide dimensioned sufficiently small to pass through the mandrel slots forming the cylindrical sectors. Where the individual coil forms are radially movable to expand the spacing for winding and subsequently transport the coil form supported wound coil toward the center axis of the sector array, other winding mechanisms can be employed than the hollow needle inasmuch as in the expanded configuration more clearance is available between sector coil form portions.

Accordingly, it is a general object of the present invention to provide for winding a set of coils for a stator winding with the coils distributed in a manner which permits their subsequent simultaneous insertion into a stator and in particular the provision of such method and apparatus which is adapted for winding sets of coils for extremely small size stators having very narrow slot dimensions into which the coil sides must be inserted, and which permits the winding to be made at very high speed and with extremely small gauge and fragile wire sizes. In combination with the winding of a set of coils in particular array, the invention provides for insertion of a set of coils simultaneously into a stator aligned on the coil form element without the introduction of any intermediate steps or supporting and guiding structures. While the insertion operation is shown as being performed immediately subsequent to the completion of. the set of coils, it will be clear from the description that the winding and inserting steps of the method could be performed as separate manufacturing operations by the utilization of a disposable or reusable coil form which is separate from and can be loaded into the winding machine for winding purposes but removed and stored with thewound coil set thereon until the insertion steps are to be performed.

A further object is to provide method and apparatus for producing wound stators in a simple and efficient manner which is adaptable to automated operation and capable of producing large or small wound stators of complex configuration which heretofore have been primarily manufactured by tedious and exacting manually performed steps which are more costly.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of the preferred form of the winding machine in accordance with the invention.

FIG. 2 is a side elevation of the machine shown in FIG. 1 with portions in section and partially broken away.

FIG. 3 is a sectional view taken along the line 33 of FIG. 1 and with certain elements omitted for clarity.

FIG. 4 is an enlarged top plan view of the winding head coil form shown in FIG. 1.

FIG. 5 is a side elevation of the winding head shown in FIG. 4.

FIGS. 6A, 6B and 6C are partial views similar to FIG. 5 but sectioned and showing in sequence an insertion operation in accordance with the invention.

FIG. 7 is a top plan view of a coil carrier used in the winding and inserting operation.

FIG. 8 is a top plan view of an alternate form of the winding head showing movable coil form elements, at exaggerated expanded positions.

FIG. 9 is a perspective view of one possible complete stator as produced in accordance with the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIGS. 1, 2 and 3, the mechanism for providing the sequence of operations necessary to wind a coil set will be described. While the disclosed embodiment is described and claimed herein with reference to horizontal and vertical elements it will be understood that these are relative terms used for conve nience of definition and they should not be interpreted as limiting the members to any absolute orientation. The apparatus has a frame comprising generally a base 11 upon which a pair of spaced parallel horizontal flange plates 12 and 13 are supported by vertical support members 14 and 15. A support column is also provided at the end of plates 12 and 13.

The spaced support plates l4, 15 are spaced by a shouldered rod 17 which spans the distance therebetween. A pivot pin 18 is journalled between the supports l4, 15 to pivotally support a beam 19 which is suspended solely by means of screw fasteners passing through the pin 18 into the beam 19.

The beam 19 has fixedly secured on its upper surface a pair of spaced support columns 21 which on their upper surfaces fixedly support a channel member 22 which has on its lower surface a channel opening in which a bar 23 is guided for sliding motion. Depending from the bar 23 are two spaced cam follower rollers 24. Also supported on the top surface of the beam 19 is a pedestal 25 on which is rotatably mounted the fixed combination of a cam drive gear 26 and a heart-shaped cam 27, the surfaces of said cam being engaged by the roller followers 24 to reciprocate the bar 23 in the channel opening of the member 22. At the end of the bar 23 opposite the location of cam rollers 24 an upward projection supports a single roller 28 which projects through a slot in the channel member 22 to roll on surface 29 of an adjustable inclined plane member 31. The member 31 is adjustably supported on upward projections of the flange plates l2, l3 and is fixed relative to the pivotal motion of beam 19. Thus rotation of the cam drive gear 26, by means to be described hereinafter, rotates the heart shaped cam 27 to cause the follower rollers 24 to displace the bar 23 in its guide channel in member 22 causing the roller 28 to reciprocate on the inclined plane surface 29 and rock the entire assembly mounted on the beam 19 about the pivot pin support 18.

The drive train for forming windings comprises a set of gears driven by a motor 32 which is suspended beneath the beam 19. The shaft of the motor 32 projects through the beam 19 and has mounted thereon a first spur gear 22 which meshes with a driven gear 33 which supports in its hub 20 a crank arm 34 for reciprocating a rod 35 through a slide support bearing 36. The location of the sliding pivot bearing 36 is determined by an adjustable slide 51 which is positioned in a slot 52 in a plate 53 mounted on top of the beam 19. Similarly the crank arm 34 can be adjusted in length by sliding arm 34 through the hub 20 to vary the crank arm radius. Both of these adjustments are secured in the desired position by suitable means such as set screws. These two adjustments provide major and minor axis dimension selection for the approximately eliptical path of a winding needle 56 which is mounted at the end of the rod 35. Needle 56 is hollow with a smooth taper bore at the end to provide a guide for the wire 57 which is wound on the boil form to be presently described. The wire 57 is unwound from a supply reel 58 and paid out through a conventional tension control device 59.

The motor shaft supports a second spur gear 37 which meshes with a larger diameter gear 38 of a concentric pair of gears 38, 43 which are rotatably supported on a plate 39. The plate 39 which supports the gears 38, 43 can be rotatably adjusted about the axis of the motor by loosening a bolt 40 which extends through a circumferential slot 4l and is threaded into the top surface of the beam 19. This adjustment alters the spacing between the axis of rotation for the gear 43 and the axis of rotation of a change gear 42 which is rotatably mounted on the beam 19. Since the slot 41 is located at a constant radius from the motor shaft, the gears 37 and 38 remain engaged for all adjustable positions of plate 39 while the distance between the rotating shafts for gear 42 and gear 43 varies by this adjustment thereby permitting different size gears 42 to be used to change the gear ratio and thereby control the turns per layer wound in each coil. The selection of the number of turns per layer in the coils which are wound by the machine permits the requirements for the copper size and cross section to be met by selecting the thickness dimension for the coil side to permit winding and insertion within the dimensional confines imposed by a particular stator structure.

The change gear 42 is fixed to a sprocket gear 45 which is connected by chain drive 46 to drive a sprocket gear 47 which is fixed to a spur gear 48. The gear 48 meshes with gear 26 to rotate the heart-shaped cam 27. As previously stated, rotation of the cam 27 reciprocates the slide 23 to rock the beam 19 around pivot axis 18. This action moves the needle 56 up and down as it rotates around its eliptical path to distribute the coil turns uniformly on the vertically extending portion of the coil form. Other mechanical motions to either uniformly or non-uniformly distribute the windings vertically as the turns are applied could, of course, be employed.

A mounting stand supports the coil form assembly for indexed rotation on the vertical central axis of a column support 60. The coil form and its mounting stand generally indicated at 61 in FIGS. 1 and 2 will be described with reference to the enlarged views thereof shown in FIGS. 4 and 5. The coil form assembly 61 comprises a plurality of movable jaws 62 which can be adjustably positioned in radial distance from the center axis of the coil form by means of a thumb wheel 63 operating the jaws 62 to move in unison after the manner of a scroll chuck. The central fixed portion of the coil form comprises an upstanding spindle having a plurality of sector projections 64 each aligned with the radius on which one of the jaws 62 moves. The projections 64 have a plurality of steps 65, 66, 67 with the diameter of the sector surfaces formed by step 65 corresponding exactly to a snug fit within the bore of the stator in which the windings are to be inserted. The general position of the stator during the insertion operation which it occupies only after the winding operation now being described is fully completed is indicated in phantom view at 68 in FIG. 5. The next larger diameter step 66 on the sectors 64 corresponds to the inner support member for the coil as actually wound. While the inner surface of the projection 64 in the region of the land 66 actually provides the supporting surface for the wire coil turns as they are wound, the outer diameter of step 66 provides an edge between the steps 65 and 66 which serves as the stop when the stator is positioned in place for coil insertion. Generally the largest diameter step 67 provides for a set of elongated holes 78 to be hereinafter described. A

The size of the coil as wound is determined by the position on the back coil supports comprising a set of pins 71 which may in the simplest form be simply snug fit into holes in the top surface of the jaws 62 but as shown in FIG. 5 extend downwardly a substantial distance to be anchored in a retractable support platform 72. The platform 72 is guided by fixed rods 73 and can be retracted by means of a set of rods 74 a sufficient distance to withdraw the top surface of the pins 71 below the level of the wound coil thereby freeing the back loop of the wound coils permitting their movement during the insertion operation. The length of the pins 71 and their supports within the winding lead are such that the different radial positions of the jaws 62 permit slight bending of the pins 71 without binding.

The winding head 61 includes a slidable rod 75 which makes a close fit with the actual bore within the sector projections 64. The rod 75 supports a cylindrical collar 76 from which upwardly project a plurality of push rods 77 which fit in semi-cylindrically shaped holes 78 in base 79 and step 67 of the coil form. Push rods 77 are adapted to insert retaining wedges 81 which are inserted in the holes 78 prior to the coil winding operation. The wedges 81 when inserted in the stator anchor and lock the windings in the respective stator slots.

The description of the winding of a set of coils with the apparatus heretofore described will now be given with the subsequent description of the insertion of the wound set of coils as a unit in an appropriate stator subsequently described with reference to FIGS. 6A6C. Initially the winding ofa set of coils will require that the physical, electrical and magnetic design of the stator be completed with the appropriate dimensions and configuration established as well as the coil parameters. The electrical requirements of the stator winding will predetermine the number of turns of wire in each coil and the wire size to be used, the distribution of the coils, the number of coils per phase, the span of each coil with respect to the stator teeth, coil overlap and other configuration parameters. Thus for a given stator, a particular coil form configuration will be dictated and this determines the dimensions of the central projections 64. These projections 64 relate to one or more stator teeth which are to be spanned by an individual coil in the set to be wound. The radial spacing of the pins 71 determines the overall size of the coil. With a particular coil form configuration on the winding head 61 the desired set of windings can be produced by the execution of the sequence immediately to be described which sequence may be performed either manually or automatically to the extent justified by the volume of units to be produced.

lnitiallya set of paper strips 80 (see FIG. 6A) utilized as wire carriers are positioned on the inner surfaces of the projections 64. For this purpose a simple spider such as shown in FIG. 7 can be punched out of a thin stiff paper sheet and the central portion thereof aligned with the plunger with the radial projections bent into a vertical position directly along the inner surfaces of the projections 64. At this time the paper wedges 81 are also loaded within the holes 78. The number of turns per layer in the coil is established by selecting the appropriate size gear 42 and by adjusting the position of plate 39 to cause engagement between the gears 42 and 43. For convenience the number of turns per layer can be directly related to the number of teeth on the gear 42 since the other gear ratios in the drive train are fixed and in particular it is possible to make the number of turns per layer equal the number of teeth on gear 42 thereby simplifying the selection of any desired number of turns per layer.

Next the path traced by the needle 56 can be set by adjusting the length of crank arm 34 and the location of the pivot bearing 36 mounted on the slide adjustment 51. The actual height of the coil caused by the level wind motion of the rocking beam 19 about pivot axis 18 can be controlled by adjusting the inclination of the member 31.

The wire 57 is threaded through the tension adjusting device 59 and through the center of needle 56 with the free end anchored to the winding head 61 temporarily so that upon traverse of the winding path by the needle 56 the wire 57 will be paid out onto the coil form elements. The first coil may be formed simply by energizing the motor 32 until a desired number of turns have been wound having the desired configuration of a coil 82. For this purpose a turn counter 83 may be geared to the rotating hub 20 or the machine may be programmed to deenergize the motor 32 and apply a braking force by means of a magnetic brake after a predetermined turn count has been completed.

After the first coil is wound the head 61 is indexed one angular position as determined manually by a detent 84 or in an automated system by a programmed step-advance power mechanism 85. This angular rotation is determined by the physical location of the spacing between the coils of the set as determined by the electrical and magnetic characteristics of the particular stator to be manufactured. As shown throughout the present disclosure a four-coil set is indicated and the spacing is thus 90. For other windings, sets having coils spaced by 30, 60 and other angular separations are obviously possible by appropriate modification of the disclosed apparatus.

For the second coil, the motor 32 is again energized for the predetermined number of turns but this time with rotation in the direction opposite that of the first coil as it is usually required to reverse the polarity of the magnetic pole developed in the teeth encompassed by a particular coil relative to adjacent poles. This sequence is repeated with indexing, reversing the motor direction of rotation and winding of a predetermined number of turns on the portion of the coil form which sectors of the particular coii form usedv These coils can be wound with a continuous unbroken wire 57 or, if desired for any reason, the wire 57 can be broken and leads for each coil in the set brought out.

After a complete set of coils has been produced on the coil form the insertion operation may be carried out. As shown herein this operation is performed in direct sequence with the completion of the winding of the set of coils but it will be readily understood that with a removable coil form insert providing the projections 64 the wound coils could be removed from the winding head and accumulated for subsequent insertion with the coil set supported during the intermediate interval on the transferrable coil form. As best seen in FIG. 6A, the wound coil 82 is supported on the inner sector portion 64 of the coil form and the outer pins 71. To relieve tension on the winding 82, the pins 71 are retracted by lowering platform 72 a distance sufficient to release all of the rear loops of the winding 82. This step is performed after the needle 56 has been retracted from a position within the coil form as shown in FIG. 6A and after the stator structure 68 has been fitted over the projections 64. The stator 68 may be retained in the position indicated in FIG. 6A by manual pressure while the insertion of the coils takes place or with a suitable edge clamp for the top surface of the stator 68.

Referring now to FIG. 68 an intermediate state of coil insertion is shown. The central plunger 75 has ad vanced the wire carrier 80 and the set of coils 82 (only one of which is shown in FIG. 6A) in an upward direction thereby threading the coil side through the slot between the stator teeth. At the same time the push rods 77 advance the paper wedges 81 in a coil retaining locking position behind the lip of the tooth face. Finally, as shown in FIG. 6C, the fully extended plunger 75 has inserted the coil side completely within the slot and the paper wire carrier 80 may be torn near its base to move the top end of the coil radially outward into its final position as shown in FIG. 6C. The coil loops on opposite sides of the stator stack may then be shaped and conformed to accommodate the coils of additional phases or otherwise secure them in a customary manner for assembly in the complete electrical machine for which they are intended. From the foregoing description it will be clear that a complete set of coils is wound in a horizontal array and a complete set is inserted in the stator as a unit by the single motion of the plunger 75 thereby simplifying the complete operation and minimizing the handling required of the set of coils. As soon as the completed stator is removed from the winding head the plunger 75 can be retracted and the pins 71 erected thereby conditioning the winding head 61 for receiving on the coil form the winding of a new set of coils and the production sequence just described can be repeated with great rapidity.

FIG. 8 shows a modification for the coil form of the winding head which permits winding of the coils at a spaced location which is different from that which they will occupy during the insertion operation. As will be clear from an examination of the structure heretofore described, the spacing between the projections 64 is required to be large enough to accommodate the thickness of the wire in two coil sides plus the thickness of the needle 56. In other words, when the complete set of coils is wound, the final turns of the needle through the slot between a pair of projections 64 will be required to pass through the space remaining after the coil sides are in place against the edges of the projections 64 on both sides of a particular slot. In miniaturized stators and high numerical tooth configurations of various devices, this physical limitation of size is severe and in some cases limits the smallest size coils that can be wound. In the construction shown in FIG 8, a set of jaws 91 is radialiy movable on base 92 as previously described except that the range of motion has been enlarged so that sector portions 93 can be located at a much larger radius than that which they occupy when brought to insertion position as indicated at 93'. With this arrangement there is obviously no significant constraint on the needle size or the coil size which can be wound on the coil form 93. For this purpose, rear pins 94 which form the rear portion of the coil form are also carried on the jaws 91 but are relatively movable with respect to the forward sector portion 93 in order to relieve tension on the turns of the wound coil thereby permitting retraction of the pins 94 prior to coil insertion. For this purpose the support for the sector portion 93 may be radially movable relative to the portion supporting pins 94 so that the spacing therebetween can be shortened after the coil is wound. Typically the two parts may be fitted with a tongue and groove track and a set screw to permit relative motion between the inner radius portion 93 and the outer radius portion 94 to provide for relief of tension after the coil is wound.

Referring now to FIG. 9 a finished stator is shown for a four pole two-phase machine. For compound windings of this type the stator would be placed on the winding head to have a first set of coils 95 inserted after which it would be indexed'through the number of physical degrees corresponding to the electrical degrees between the winding phases and a second set of windings 96 would be inserted. Each set of windings consists of four coils and the bottom set 95 is inserted first. As indicated in FIG. 9 the coil form sector 64 bridges the teeth and slots which extend between the particular slots in which the respective sides of a coil are to be inserted. Thus the vertical edges of the sector portion 64 act as guides to direct the coil sides into the correct slot as the plunger advances to raise the coil set up through the central bore of the stator.

While it will be apparent that many modifications may be made in the disclosed apparatus for achieving the results desired for the invention it will in particular be noted that the variety of coil and stator combinations which can be wound and inserted in accordance with the invention is almost unlimited. Thus the coil form sector portions 64 may be any desired shape and in particular if a single tooth is to support a coil, the projections 64 will correspond only to the width of a single tooth. 0n the other hand for distributed windings the sector portions 64 will span the teeth and the included slots about which a coil is to be placed. It should also be noted that the invention maybe implemented with more than one winding needle operative in unison at spaced positions around the winding head 61 which is particularly useful for high production rates or for complex windings such as employed in synchros. Similarly, the overlap of a plurality of sets of coils may be established on the coil form configuration for ultimate insertion in overlapped relation by a single insertion stroke. Basically these elaborations and expansions of the basic idea of winding a coil unit comprised of a horizontally distributed set of coils for simultaneous insertiton in a stator constitute modifications which are clearly within the scope of the generic invention and the appended claims should be so interpreted.

What is claimed is: 1. The method of winding a multicoil winding and inserting the coils in the slots of a stator of an electrical machine comprising the steps of:

winding on a coil form a set of coils arrayed in horizontal sectors around a vertical center line, the length of the turns in each coil corresponding approximately to the average distance around the one or more teeth encompassed by each said coil when said coil is in place in the stator slots,

each coil having multiple turns of coil cross section as determined by the electrical requirements of said machine, the height and thickness dimensions of said cross section being selected to permit said thickness dimension for the coil sides of said set of coils which are to occupy a given slot of said stator to pass through the gap between adjacent tooth faces simultaneously,

supporting the wound array of coils on said coil form which has a guide member extending vertically through each coil, the shape of each said member corresponding to the circumferential distance occupied by one or more teeth between the slots in which the coil sides of each coil are to lie andextending above the wound coil approximately the stack height of said stator;

subsequently supporting said stator in axial alignment above the horizontal array of wound coils on said coil form with the set of said one or more teeth in registry with the respective extended ends of said guide members which extend through the stator bore;

urging the portion of said set of coils within said guide members to move axially upwardly as a unit through the central bore of said stator to cause the coil sides to be guided by said guide sector members into the slots adjacent to said one or more teeth bridged by said members respectively; and

radially moving the looped ends of said coils lying above said slots on the top side of said stator to locate said set of coils in operative position on said stator.

2. Apparatus for winding a related set of coils comprising:

a set of coil forms symmetrically arranged in sectors relative to an axis, each of said forms having turn supporting members disposed at inner and outer radii from and parallel to said axis with the perimeter path around said members determining the shape of said coils;

means for winding multiturn coils on each of said coil forms with the turns distributed normal to the plane of winding; and

means for relatively moving the inner and outer radii portions of said turn supporting members for relieving the winding tension of said coils while still supporting said coils on said inner radii portions of said members, said inner radius members projecting beyond the distributed height of the wound coils and having a predetermined shape to act as a guide for said coils when said coils are displaced axially on said coil form.

3. Apparatus according to claim 2 wherein said means for winding comprises:

a hollow needle supported generally parallel to said axis;

means for moving said needle repeatedly in a path around one of said coil forms and passing between said one coil form and the coil forms in adjacent sectors;

means for oscillating said needle substantially normal to the plane of said path in timed relation to repetitive traverses of said path by said needle;

means for indexing all of said coil forms in sequence to winding position relative to the path of said needle; and

means for feeding wire through said needle to be wound on said coil forms.

4. Apparatus according to claim 3 and including a plunger axially movable on said axis and closely fitting within said inner radius members for moving said wound coils axially on said coil forms.

5. Apparatus according to claim 4 and including inner radius members as supports for a stator and means for inserting the coils.

6. Apparatus according to claim 4 in which said inner radius members are supported on a base which contains a set of holes at a predetermined radius from and parallel to said axis and including a plurality of rods projecting into said holes, said rods supported for movement in conjunction with said plunger to eject into said stator winding-retaining wedges previously loaded into said holes.

7. Apparatus according to claim 2 in which said coil forms are each supported for radial movement relative to said axis; and means for moving all of said coil forms to an expanded large radius position to facilitate passage of a winding means between adjacent coil forms.

8. A coil winding machine comprising:

a base;

a beam mounted for pivotal motion on said base;

a drive motor mounted on said beam;

a winding rod pivotally and slidably supported in a bearing at one end of said beam, said rod extending beyond said end of said beam;

a hollow needle supported on the extended end of said rod;

a crank arm connected to the other end of said rod and rotatable to drive said rod in said bearing to move said needle repeatedly in a generally eliptical path;

means for supplying wire to be wound through said needle as said rod moves said needle on said path;

first drive. train betwen said motor and said crank arm;

.beam tilting means for rocking said beam about its pivot axis; and

a second drive train from said motor to said beam tiling means for rocking said beam in predetermined relation to the rotation of said needle on said path.

9. Apparatus according to claim 8 and including:

a multicoil set of coil forms positioned beneath said needle each of said coil forms having projections generally parallel to said needle and defining the perimeter of wire turns wound thereon by said needle as it traverses said eliptical path;

means for indexing said coil forms in sequence into winding position beneath the path of said needle; and

means for relieving tension in coils wound on said coil form to facilitate removal of said coils.

10. Apparatus according to claim 9, in which said means for relieving tension comprises means for relamounted and aligned on said support.

12. Apparatus according to claim 11 in which said means for relieving tension comprises means for relatively moving said projections to decrease the length of said perimeter, and including means for moving each of said coil forms radially away from the axis of said bore to expanded coil winding position and return to said axial bore defining position for removing said wound coils. 

1. The method of winding a multicoil winding and inserting the coils in the slots of a stator of an electrical machine comprising the steps of: winding on a coil form a set of coils arrayed in horizontal sectors around a vertical center line, the length of the turns in each coil corresponding approximately to the average distance around the one or more teeth encompassed by each said coil when said coil is in place in the stator slots, each coil having multiple turns of coil cross section as determined by the electrical requirements of said machine, the height and thickness dimensions of said cross section being selected to permit said thickness dimension for the coil sides of said set of coils which are to occupy a given slot of said stator to pass through the gap between adjacent tooth faces simultaneously, supporting the wound array of coils on said coil form which has a guide member extending vertically through each coil, the shape of each said member corresponding to the circumferential distance occupied by one or more teeth between the slots in which the coil sides of each coil are to lie and extending above the wound coil approximately the stack height of said stator; subsequently supporting said stator in axial alignment above the horizontal array of wound coils on said coil form with the set of said one or more teeth in registry with the respective extended ends of said guide members which extend through the stator bore; urging the portion of said set of coils within said guide members to move axially upwardly as a unit through the central bore of said stator to cause the coil sides to be guided by said guide sector members into the slots adjacent to said one or more teeth bridged by said members respectively; and radially moving the looped ends of said coils lying above said slots on the top side of said stator to locate said set of coils in operative position on said stator.
 2. Apparatus for winding a related set of coils comprising: a set of coil forms symmetrically arranged in sectors relative to an axis, each of said forms having turn supporting members disposed at inner and outer radii from and parallel to said axis with the perimeter path around said members determining the shape of said coils; means for winding multiturn coils on each of said coil forms with the turns distributed normal to the plane of winding; and means for relatively moving the inner and outer radii portions of said turn supporting members for relieving the winding tension of said coils while still supporting said coils on said inner radii portions of said members, said inner radius members projecting beyond the distributed height of the wound coils and having a predetermined shape to act as a guide for said coils when said coils are displaced axially on said coil form.
 3. Apparatus according to claim 2 wherein said means for winding comprises: a hollow needle supported generally parallel to said axis; means for moving said needle repeatedly in a path around one of said coil forms and passing between said one coil form and the coil forms in adjacent sectors; means for oscillating said needle substantially normal to the plane of said path in timed relation to repetitive traverses of said path by said needle; means for indexing all of said coil forms in sequence to winding position relative to the path of said needle; and means for feeding wire through said needle to be wound on said coil forms.
 4. Apparatus according to claim 3 and including a plunger axially movable on said axis and closely fitting within said inner radius members for moving said wound coils axially on said coil forms.
 5. Apparatus according to claim 4 and including inner radius members as supports for a stator and means for inserting the coils.
 6. Apparatus according to claim 4 in which said inner radius members are supported on a base which contains a set of holes at a predetermined radius from and parallel to said axis and including a plurality of rods projecting into said holes, said rods supported for movement in conjunction with said plunger to eject into said stator winding-retaining wedges previously loaded into said holes.
 7. Apparatus according to claim 2 in which said coil forms are each supported for radial movement relative to said axis; and means for moving all of said coil forms to an expanded large radius position to facilitate passage of a winding means between adjacent coil forms.
 8. A coil winding machine comprising: a base; a beam mounted for pivotal motion on said base; a drive motor mounted on said beam; a winding rod pivotally and slidably supported in a bearing at one end of said beam, said rod extending beyond said end of said beam; a hollow needle supported on the extended end of said rod; a crank arm connected to the other end of said rod and rotatable to drive said rod in said bearing to move said needle repeatedly in a generally eliptical path; means for supplying wire to be wound through said needle as said rod moves said needle on said path; first drive train betwen said motor and said crank arm; beam tilting means for rocking said beam about its pivot axis; and a second drive train from said motor to said beam tiling means for rocking said beam in predetermined relation to the rotation of said needle on said path.
 9. Apparatus according to claim 8 and including: a multicoil set of coil forms positioned beneath said needle each of said coil forms having projections generally parallel to said needle and defining the perimeter of wire turns wound thereon by said needle as it traverses said eliptical path; means for indexing said coil forms in sequence into winding position beneath the path of said needle; and means for relieving tension in coils wound on said coil form to facilitate removal of said coils.
 10. Apparatus according to claim 9, in which said means for relieving tension comprises means for relatively moving said projections to decrease the length of said perimeter.
 11. Apparatus according to claim 9 in which the inner projections of said coil forms define an axial bore and extend above the winding zone to define a stator support; and including a plunger slidable in said axial bore for simultaneously stripping a set of wound coils off said projections and into the slots of a stAtor mounted and aligned on said support.
 12. Apparatus according to claim 11 in which said means for relieving tension comprises means for relatively moving said projections to decrease the length of said perimeter, and including means for moving each of said coil forms radially away from the axis of said bore to expanded coil winding position and return to said axial bore defining position for removing said wound coils. 